Seam joining a waterproof laminate with textile layer made of multi-component yarns

ABSTRACT

The invention discloses a textile laminate ( 1, 400, 450 ) with a first layer ( 5 ) comprising a waterproof and preferably breathable functional layer ( 10, 20 ) and a second layer ( 30 ) comprising at least a first component and a second component. The first component is stable to a first temperature and the second component melts at a lower second temperature. In one embodiment of the invention, the first component is polyester and the second component may be a thermoplastic such as copolyester, polyamide, copolyamide or polyethylene. The textile laminate ( 1 ) is particularly advantageous when two of such laminates ( 1, 400, 450 ) have to be joined or fused together. In this case a waterproof seam is created at the seam ( 500 ) between the two laminates ( 1, 400, 500 ).

FIELD OF THE INVENTION

The invention relates to a seam formed between when two or morelaminates are joined together.

PRIOR ART

High technology apparel garments made of waterproof textile laminatesare state of the art. These laminates contain a waterproof, windproofand breathable membrane onto which is laminated at least one textilelayer.

The joining together of two textile laminates present a problem if theseam at which the two textile laminates are to be sealed is to be madewaterproof. Various methods have been tried. For example, W.L.Gore &Associates has developed a method in which two GORE-TEX® laminates areheat sealed at a seam using a GORE-SEAM® seam sealing tape.

The principles of sealing are well known. Generally, to get a sealedjoint or a seam, a sealant, an energy source, and structural joining arerequired. There are a number of prior art methods which demonstratethis. The sealants available are numerous and can be added to thelaminates or are part of the native materials. The energy sources whichcan be used for sealing are numerous and include, but are not limited toheated tools, radio frequency, thermal impluse, and ultrasonic weldingmethods. Under the proper conditions structural joining of the textilelaminates will take place and a joint or seam will be formed.

The prior art discloses a number of seam-forming methods involving thefusion of a thin strip of thermoplastic material to bind two layers oftextile materials together and thus form a seam. These are disclosed,for example, in U.S. Pat. No. 3,387,307 (Blatz) assigned to Handgards,Inc. A similar method is taught in GB-A-1 465 343 in which a thinthermoplastic strip is placed between two fabric pieces to form theseam. The use of this method results in a stiff seam being formedbetween the two fabric pieces.

Other prior art is known in which the laminates are adhered togetherusing adhesives. European Patent EP-B-0 345 730 (Kleis) assigned toW.L.Gore & Associates GmbH teaches the use of adhesive beads to producethe seams in a glove or other clothing application. Glove insertproducts made according to this invention are available from W.L.Gore &Associates GmbH in Feldkirchen, Germany, under the trade mark DIRECTGRIP®. In order to ensure absolute waterproofness of the seams, it isnecessary for the adhesive to penetrate the whole depth of the textilelayer up to the membrane. In particular for voluminous textile layer,the seams have to be glued over a wide area. The seams thus produced arestrong but relatively stiff and uncomfortable.

U.S. Pat. No. 5,003,902 describes a seam construction for use onprotective clothing which involves overlapping the fabric pieces andbonding them together by use of a melt-adhesive film between them. Aliquid-proof thread is sewn through the overlap in order to secure thetwo pieces of fabric to each other. The completed seam is then heated tomelt-bond the adhesive film to the fabric pieces and to seal anyapertures left by the sewing thread. The seams produced according to theteachings of this patent are also strong but relatively stiff andtherefore uncomfortable to the wearer.

One of the problems encountered with these prior art seam sealingmethods for waterproof laminates is that the seams have had to be fairlywide in order to ensure that the seams are waterproof. This results in astiff seam which reduces the comfort of the garment to the wearer. In,for example, sock or glove applications, the width and/or the stiffnessof the seams is particularly noticeable. Some attempts have been made atproducing narrower seams. However, these have not been durablywaterproof or softer because of the added sealant material.

It has been possible with prior art methods to construct narrower seamswhich are waterproof and flexible. However, these seams have proven tobe weak in the transverse, i.e. cross-seam, direction. This weaknessresults in a lack of durable waterproofness.

U.S. Pat. No. 3,625,790 (Ayres) teaches a glove made of a non-breathablelaminate of an elastic fabric and a thermoplastic layer. Two pieces of alaminate are welded together to form a glove in which the seams areformed by fusion of the thermoplastic layers using dielectric heatingmeans. The use of electromagnetic waves at radio frequencies to formseams limited to those materials textiles which incorporate materialshaving dipolar molecules, such as polyvinyl chloride (PVC) or somepolyurethanes (PU). This insert seam while flexible is not very strong.Particularly in manufacturing processes this is a severe disadvantagesince the textile laminates have to be handled carefully in order toavoid damage.

Further prior art known to the inventors includes U.S. Pat. No.4,545,841 (Jackrel) which teaches an insert that is formed by heatsealing and U.S. Pat. No. 5,036,551 (Dailey) which teaches a glove thatis formed by heat sealing a laminate. In both these examples, the insertseam while flexible is not very strong.

The problem with the prior art examples in which sealant material isadded to form the seam is that the seam whilst strong is not flexible,i.e. they feel stiff to the wearer. The use of these seams is thuslimited because of the discomfort to the wearer, especially in thoseapplications in which a close fit is required.

The problem with the prior art examples in which the sealant material issupplied from the native material is that the seams whilst flexible areweak. The use of these seams is limited because of durability in toughapplications and, particularly in manufacturing processes this is asevere disadvantage since the textile laminates in which such seams areincorporated have to be carefully handled in order to avoid damage.

Further problems with prior art seams, such as those made from polyamideor polyester is that these materials tend to shrink when these materialsare heated to their melt points. This causes the laminates to deform.

There is therefore a need for a strong, durable and flexible seam fortough end uses and close fitting applications.

SUMMARY OF THE INVENTION

It is therefore an object of this invention to improve the comfort ofthe seams in garments made of waterproof laminates.

It is furthermore an object of this invention to reduce the width of theseams in garments made of waterproof laminates.

It is therefore an object of this invention to produce long-lasting,durable seams in garments made of waterproof laminates.

It is furthermore an object of the invention to provide seams which areboth strong and flexible.

It is furthermore an object of the invention to provide seams which arestrong in the transverse (cross-seam) directions.

A further object of the invention is to provide seams which have a lowshrinkage.

A further object of the invention is to provide seams which have a highstretch.

It is preferred that the laminates from which the seams are to be madeare breathable, i.e. water vapour permeable.

These and other objects of the invention are solved by providing alaminate with a waterproof and preferably breathable functional layer onwhich is laminated a second textile layer comprising at least a firstcomponent and a second component, preferably in the form of a conjugatefibre. The first component is made of a material which is stable to afirst temperature and the second component is made of a material whichmelts at a second temperature. The first temperature is higher than thesecond temperature. Such a laminate can be supplied with energy, e.g. byheating, to reach a temperature higher than the second temperature butlower than the first temperature. The second component melts andprovides sealant material (adhesive) for joining the laminate to anothersubstrate or a laminate.

Both the first component and the second component participate in thestructural joint. The second component encapsulates the first componentwhilst the first component remains stable. The second component providesthe waterproof barrier and the first component provides structure andstrength to the seam.

Using these laminates, it is not necessary to use an additionalthermoplastic strip to provide adhesive material to form the seam.Rather the material of the laminate (the native material) forms the seamitself. This leads to a reduction in manufacturing complexity of theseam and a reduction in seam bulk thus reducing the stiffness of theseam and increased comfort to the wearer. There is also an improvementin the assembly at the factory making, for example, gloves with seams ofthe invention since these seams are more tolerant of external stresses.

The seams formed by this laminate are found to be high in transverseseam strength and longitudinal strain and also to be flexible.

Such laminates are known from U.S. Pat. No. 5,662,978 (Brown et al.)assigned to Kimberly-Clark Worldwide, Inc., and in which conjugatespunbound fibres of polypropylene and polyethylene are used to form anon-woven textile layer. This textile layer is laminated to a polyolefinfilm, particularly polyethylene. The laminates formed according to theteachings of this patent are used for manufacturing a protective coversand not for the production of articles of clothing. There are noteachings in this patent that the laminate of this invention can be usedto form comfortable and hard-wearing seams, such as those used in theproduction of articles, e.g. articles of clothing.

A similar laminate is further known from U.S. Pat. No. 5,503,907(Gessner) assigned to Fiberweb North America, Inc., in which a non-woventextile layer of multi-component fibres is laminated to a microporouslayer. The lower melting component of the multi-component fibre taughtin this patent application is used to form the bond of the textile layerwith the microporous layer. The higher melting component retains itssubstantially continuous fibrous form to provide a strengthening andreinforcing function in the laminate. There are no teachings in thispatent concerning the production of seams from laminates used, forexample, in clothing applications.

Similarly German Patent DE-C-196 32 312 (Tebbe) teaches a glove made ofa laminate of a polypropylene foil onto which is laminated a textilelayer of cotton or cellulose. The textile layer further includespolypropylene fibres in a blend in order to improve the adhesion betweenthe polypropylene foil and the textile layer. The glove is made bywelding two pieces of laminate cut on the polypropylene foil side intoglove shapes together by radio frequency welding. In this example, thetextile layer is placed on the exterior of the glove and thepolypropylene foil is on the inside of the glove. The textile layer thusdoes not participate in the welding together of the two textilelaminates.

The seams formed from the laminates of the invention are sufficientlywaterproof that they are able to withstand a water entry pressure of atleast 0.07 bar and preferably at least 0.13 bar according to the sutertest described below. Furthermore the seams are strong and flexible asdemonstrated by the stiffness tests and the Instron tests below.

In the laminate, the second (low melting point) component is preferablymeltable at a temperature in the range from 80° C. to 170° C. whilst thefirst (high melting point) component is stable to a temperature of atleast 140° C. For a reliable seam to be formed the difference intemperature between the first temperature and the second temperature isat least 20° C.

In one embodiment of the invention, the second layer further includes apropellant or foaming agent which is activatable by activation means. Onactivation this propellant produces a gas which in combination with themelted second component provides a foam-like substance with closedcells. The closed cells ensure that the seam remains waterproof but theseam is resilient but also “spongy” and thus soft. The seam is thereforecomfortable for the wearer of apparel made from the laminate.

According to one embodiment of the invention the second layer iscomposed of a plurality of yarns in the form of strands, filaments,threads or fibres. The second component in the second layer is athermoplastic which is selected from the group of thermoplasticscomprising co-polyester, polyamide, co-polyamide or polyolefin. In thepreferred embodiment of the invention the second component is apolyethylene a polyamide 6.0.

The first component is selected from the group of polymers comprisingcellulose, protein fibers including wool and silk, polyolefins includingpolypropylene and polyethylene, polyester, co-polyester, polyamide orco-polyamide. Preferably the first component is polyamide 6.6.

The yarn in the second layer is in one embodiment a conjugate fibrecomprising the first component and the second component. A conjugatefibre having two components is sometimes termed a bi-component fibre.Suitable bi-component structures for use in the invention include aneccentric-sheath-core configuration, a concentric sheath-coreconfiguration, wherein the second component forms the cover, an“island-in-sea” configuration, a wedge-core configuration, a wedgeconfiguration or a “side-by-side” configuration. In the preferredembodiment of the invention, the fibre used has a sheath-coreconfiguration.

In the embodiment of the invention with a propellant, the propellant isactivated at a third temperature, the third temperature beingintermediate between the second temperature and the first temperature.The propellant can be an integral part of the second component and isselected from the group of propellants consisting of azodicarbonamide,ammonium hydrogen carbonate, toluolsulfohydrazin or diazoaminobenzol. Inthe preferred embodiment of the invention the propellant isazodicarbonamide.

The functional layer included in the laminate is a membrane or a film.The functional layer is selected from the group of materials consistingof polyester, polyamide polyketone, polysulfones, polycarbonates,fluoropolymers, polyacrylates, co-polyetheresters, co-polyetheramides,polyurethane, polyvinylchloride (PVC), polytetrafluoroethylene orpolyolefins Preferably the functional layer is made from expanded PTFE.Expanded PTFE is known to be very waterproof and highly breathable. Itprovides the laminate with an water vapour transmission rate of lessthan 150 (m².Pa)/m and a water entry pressure of greater than 0.13 bar.

The invention also provides a method for sealing detected pinholes inwaterproof laminates by allowing one component in the textile layer tobe melted to flow and seal the detected pinhole.

DESCRIPTION OF THE DRAWINGS

FIG. 1 shows the textile laminate of the invention.

FIG. 2 shows a method of manufacture of the composite layer of thetextile laminate.

FIG. 3 shows a method of lamination of textiles onto the composite layerof the textile laminate.

FIG. 4 shows the method of formation of a seal between two textilelaminates according to the invention.

FIG. 5 shows an embodiment of the invention in which the bicomponentlayer is fused to the backer fabric.

FIG. 6 shows an embodiment of the invention in which the textilelaminate is used as a seam sealing tape.

FIG. 7 shows an embodiment of the invention in which a pinhole is sealedby heating the bicomponent layer of the textile laminate.

DEFINITIONS OF TEST METHODS

Waterproofness

Waterproof as used herein is meant having water-penetration-resistance(hydrostatic resistance) of 0.13 bar or more. This measurement iscarried out on laminates by placing a test sample of the laminate withan area of 100 cm² under increasing water pressure. For this purpose,distilled water with a temperature of 20±2° C. is used and the rate ofincrease of the water pressure was 60±3 cmH₂O/min. The water penetrationresistance of the sample is then the pressure at which water appears onthe opposite side of the sample. The exact method of carrying out thistest is given in the ISO Standard No. 811 from 1981.

The measurement is carried out on seams by the so-called suter test inwhich a test sample of the laminate including the seam is stretched overa holder. Distilled water with a temperature of 20±2° C. was placedunder a pressure of 0.13 bar on one side of the seam and the test sampleleft for at least three minutes. The other side of the seam wasinvestigated using a filter paper to see whether water penetrationthrough the seam had occurred.

Water Vapour Permeability, i.e. Breathability

Water vapour permeable as used herein is meant having awater-vapour-transmission rate (Ret) of under 150 (m².Pa)/W. The watervapour transmission rate is measured using the Hohenstein MDM Dry Methodwhich is explained in the Standard-Prüfvorschrit (Standard Test Rules)No. BPI 1.4 dated September 1987 and issued by theBekleidungsphysiologisches Instituts e.V. Hohenstein, Germany.

Weight of the Fabric

The weight of the fabric was determined using a 2.54 cm×7.63 cm samplewhich had been conditioned at 24±2° C. and 65±2% relative humidity priorto testing. In the sampling pattern used, five specimens of the rawgoods or three specimens of the laminate and laminate with seams weretested and the mean of the results together with the standard deviationwas calculated. Any balance accurate to 0.01 g with a draft cover can beused. Further details of the test method are given in ASTM D 3776-96Option C.

Thickness of the Seam

The so-called Snap Gauge Method was used according to ASTM D 1777-64(re-approved 1975) using a Peacock 20-360 Snap Gauge (M-213) tester. Aspecimen of at least 2.54 cm×7.62 cm was used which been conditioned at24±2° C. and 65±2% relative humidity prior to testing. The presser footof the tester was lowered onto the specimen without impact. After fiveseconds a reading was taken. In the sampling pattern used, the thicknesswas measured at three locations along the length of the specimen and thethree readings averaged in order to obtain the thickness of the seam.

Width of Seam

The width was measured along the length of a specimen in three locationsand averaged to get the seam width for that specimen. Three specimenswere tested and the mean of the three results was calculated. The widthwas measured to the nearest mm using a scale.

Length of the Seam

The length was measured on each specimen. Three specimens were testedand the mean of the three results was calculated. The length wasmeasured to the nearest mm using a scale.

Shrinkage of Seam

The percent seam shrinkage was calculated using the following formula:

% shrinkage=(1-(seam area/theoretical seam area))*100 %.

The seam area is seam width multiplied by the seam length. Thetheoretical area is for the foot print of the Theller heat seal machine.The foot print used was 12 mm by 131 mm.

Strength of Seam

This was measured using a an Instron 1122 Tester using 1″ (2.54 cm) jawfaces connected to a computer. Three 7.62×2.54 cm samples were cut fromthe seam. The samples were conditioned at 24±2° C. and 65±2% relativehumidity prior to testing.

Cantilever Stiffness Test

This is carried out using an FRL Cantilever Tester with samples in whichthe longer edge is laid parallel to the test direction. Prior totesting, the seam width (in mm) and the seam thickness (in mm) weremeasured using the methods described above. The specimens areconditioned at 24±2° C. and 65±2% relative humidity prior to testing.The angle indicator is 41.5°. After switching the apparatus on themovable weight will move to the right until the sample bendssufficiently to reach the indication bar at which point the apparatus isswitched off and the length of the overhang measured. The flex stiffness(G) is then calculated from the following formula:

G=L/(W*T)

in which L=length of overhang (cm), W=width of seam (mm), andT=thickness of seam (mm).

Three specimens manufactured in the machine direction (i.e. along seam)and three specimens manufactured in the transverse direction (i.e. crossseam) were measured and the average calculated. The seam was orientedwithin the cantilever tester in both cases in the same direction.

Functional Layer

The term functional layer is used to denote a layer which had theproperties that it is both waterproof and water-vapour permeable.

Yarn

The term yarn in the description is used to describe the continuousstrands of material which are made into the textile. It includesstrands, filaments, fibres and the like.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 shows a textile laminate 1. The textile laminate comprises acomposite layer 5 formed from a porous polymeric layer 10 and acontinuous non-porous hydrophilic water vapour permeable polymer layer20. On the first side of the composite layer 5 a bicomponent strandlayer 30 comprising one or more bicomponent yams is placed and on thesecond side of the composite layer is a backer fabric 40 is placed.

The porous polymeric layer 10 used in this invention is a microporouspolymer membrane having a microscopic structure of open, interconnectingmicro voids. It exhibits air permeability and as such imparts, or doesnot impair, water vapour permeability. The microporous membrane used inthe laminate 5 described herein is typically of a thickness of 5 μm to125 μm, most preferably of the order of about 5 μm to 25 μm. The usefulpolymers of the microporous membrane material include plastic polymersas well as elastomeric polymers. Examples of suitable polymers includepolyesters, polyamide, polyolefins, polyketones, polysulfones,polycarbonates, fluoropolymers, polyacrylates, polyurethanes,co-polyetheresters, co-polyetheramides and the like. The preferredpolymers are plastic polymers.

The preferred microporous polymer membrane material is expandedmicroporous polytetrafluoroethylene (PTFE). These materials arecharacterised by a multiplicity of open, interconnecting microscopicvoids, high void volume, high strength, soft, flexible, stable chemicalproperties, high water vapour transfer and a surface that exhibits goodcontamination control characteristics. U.S. Pat. No. 3,953,566 and U.S.Pat. No. 4,187,390 describe the preparation of such microporous expandedpolytetrafluoroethylene membranes and are incorporated herein byreference.

The continuous water vapour permeable polymer layer 20 is a hydrophilicpolymer. The hydrophilic layer selectively transports water by diffusionbut does not support pressure-driven liquid or air flow. Thereforemoisture, i.e. water vapour, is transported but the continuous layer ofthe polymer precludes the passage of such things as air-borne particles,micro-organisms, oils or other contaminants. This characteristic impartsto the textile including the polymer layer 20 and in turn to articlesmade from it, such as socks or gloves, good contamination controlcharacteristics by functioning as a barrier to contaminants of allsizes. Furthermore the water vapour transmitting characteristics of thematerial allow for comfort characteristics to the wearer.

The continuous water vapour permeable polymer layer 20 is typically of athickness of between 5 μm and 50 μm, preferably between about 10 μm and25 μm. This thickness has been found to be a good practical balance toyield satisfactory durability, continuity and rate of water vapourtransmission.

Although not limited to them, the continuous water-vapour permeablepolymers At most useful herein are those of the polyurethane family, thesilicone family, the co-polyetherester family or the co-polyetheresteramide family. Suitable co-polyetherester hydrophilic composition may befound in the teachings of U.S. Pat. No. 4,493,870 (Vrouenraets) and U.S.Pat. No. 4,725,481 (Ostapachenko). Suitable hydrophilic compositions aredescribed in U.S. Pat. No. 4,2340,838 (Foy et al.). Suitablepolyurethanes maybe found in U.S. Pat. No. 4,194,041 (Gore). A preferredclass of continuous, water vapour permeable polymers are polyurethane,especially those containing oxyethylene units, such as described in U.S.Pat. No. 4,532,316 (Henn). Typically these materials comprise acomposition having a high concentration of oxyethylene units to imparthydrophilicity to the polymer. The concentration of oxyethylene units istypically greater than 45% by weight of the base polymer, preferablygreater than 60%, most preferably greater than 70%.

The composite layer 5 used to make the laminate 1 can be preparedaccording to the teachings of U.S. Pat. No. 5,026,591 (Henn et al.).This method is illustrated but not limited to the following descriptionof a four roll stack as shown in FIG. 2. Metered control of the moltenwater vapour permeable polymer 55 is provided for by a gravure roll 70and a doctor blade/polymer reservoir 60. The water vapour permeablepolymer 55 is applied as a thin, continuous liquid film 61 to thecontinuously moving porous polymer membrane 80 in the nip 62 between tworotating rolls 90, 100; the first one of the rotating rolls 90 havingbeen coated with the liquid polymer and the second one of the rotatingrolls 100 providing support so as to force the liquid polymer partiallyinto the porous structure of the polymer membrane 80.

The textile laminate 1 is preferably provided with a backer fabric 40.The backer fabric 40 may be either woven, non-woven or knitted and maybe made from a wide variety of materials such as polyester, polyamide(Nylon), polyolefins and the like.

The backer fabric 40 is laminated to the second side of the compositelayer 5 by a standard lamination process such as that shown in FIG. 3.In the process, a dot pattern of heat-curing adhesive 115 from a doctorknife/adhesive reservoir 130 is metered onto the second side of thecomposite layer 5 by a gravure roll 120. The composite layer 5 is heldunder minimal tension against the gravure roll 120 by a low durometerrubber roll 140 at a pressure sufficient to effect removal of theadhesive dots onto the second side of the composite layer 5.

On exiting a printing nip 150, the adhesive dot coated composite layer160 is brought to a laminating roll 170 where it is brought in intimatecontact with the backer fabric 40 provided from a storage roll 180. Thelaminate 190 created by the uncured adhesive is then wrapped around aheating roll 200 and heated to a temperature suitable for curing theadhesive, e.g. around 125° C. Upon exiting the nip 210 between the roll200 and a pressure roll 215, the laminate 220 is taken up on a storageroll 230.

The bicomponent layer 30 is a woven, non-woven or knitted textile layermade from strands, filaments, threads or fibres having at least twocomponents. The first component is a material which is stable, i.e. doesnot melt or otherwise disintegrate, to a high temperature, e.g. around230° C. The second component is a material with a low meltingtemperature, e.g. around 110° C. The two components in the bi-componentlayer may be made up of two different types of strands, filaments,threads or fibres. More preferably, a bi-component yarn is used. Thebi-component yarn may have either a core-sheath structure an“island-in-the-sea” structure or a “side-by-side” structure. Table 1shows a number of possible bi-component yams which may be used in thisinvention.

TABLE 1 melting temperature Supplier/ Polymers of low melt structure/Trade Name low/high component construction Hoechst/ Co-PET/PET, 130 or170° C. Bicomponent Celanese PE/PET, 127° C. filament (Trevira “V 721-PP/PET, 166° C. (sheath/core) or 724”) PA12 or 6/PET 178 or 221° C.filament bend PBT 227° C. Hänsel/Spunfab Co-PA, Co-  95-170° C.Monofil/melt blown PET 100% low melting 100% Far Eastern PE/PP, 130° C.sheath/core Textile PE/PET, 190° C. 10-70% low (“EASTLON”) Co-PET/PETmelting (Du Pont) PA 6/PA 6.6 218° C. sheath/core EMS-Chemie Co-PA/PET 85 or 140° C. PET-core (20%), (“GRILON”) (monofil.) Co-PA-sheath 85-160° C. (80%) or (multifil.) 100% low melting Danaklon “AL- PE/PP125-145° C. sheath/core Adhesion-C fibres”

It should be noted that it is difficult to define an exact melting pointfor polymers. A better term would be to use the expression melting rangeas indicated in the above table. The term melting point is used in thecontext of this application to describe the temperature above which thepolymer flows sufficiently to form a seam.

The bi-component layer 30 is described in this description as having twocomponents. It should be note that the bi-component layer 30 may bereplaced by a tri-component layer containing three components or amulti-component layer containing a plurality of components. Moregenerally such multi-component layers are made from conjugate fibres asknown from U.S. Pat No. 5,662,978 Brown et al).

The bi-component layer 30 is laminated onto the first side of thecomposite layer 5 or onto the porous polymeric layer 10 by a laminationprocess similar to that described above with reference to FIG. 3. Caremust be taken during the lamination process that the low meltingtemperature component does not melt during lamination of thebi-component layer 30 onto the composite layer 5.

The bi-component layer 30 may additionally include a propellant whichproduces a gas when activated. Known means for activating the propellantare either heating the activation means or irradiating the propellantby, for example, an electron beam or high frequency electromagneticradiation. After activation of the propellant and melting of the secondlow melting temperature component, the gas produced by the propellantproduces in combination with the melted low melting temperaturecomponent a closed-pore foam as will be described later. Knownpropellants which may be used in the invention are azodicarbonamide(ADC), ammonium hydrogen carbonate (NH₄CO₃), Toluolsulfohydrazin (TSH)or Diazoaminobenzol.

Several methods are known for ensuring that the propellant is insertedinto the layer.

In the first method, the propellant is added to the master batch fromwhich at least one of the fibres forming the bi-component layer 30 is tobe spun. The blend of propellant and fibre material is subsequently spunconventionally using a nozzle.

A second method includes adding the propellant as a powder to thespinning extruding in the nozzle prior to the spinning of one of thefibres forming the bicomponent layer 30. In both the first and secondmethod, the propellant is evenly distributed throughout thecross-section of the fibre. The propellant is thus integrallyincorporated within the fibre.

A third method involves coating a monofilament or a multifilament yarnas it passes a nozzle. An extruder presses a hot melt containing apropellant which flows around the yarn and coats the yarn. Using thismethod only the outside of the yarn is coated with the propellant.

In the preferred embodiment of the invention, the propellant isheat-activated and the activation temperature is chosen to be at leastaround 20° C. higher than the melting temperature of the low meltingtemperature component. The activation temperature is furthermore chosento be substantially below the melting temperature of the high meltingtemperature component.

The textile laminate 1 is particularly useful in applications in whichtwo textile laminates have to be joined or fused together as isillustrated in FIG. 4. In this example a first textile laminate 400 isto be joined to a second textile laminate 450. The first textilelaminate 400 comprises a first composite layer 410 including a porouspolymeric layer 415, a first backer fabric 420 laminated to the secondside of the first composite layer 410 and a first bi-component layer 430laminated to the first side of the first composite layer 410. The secondtextile laminate 450 comprises a second composite layer 460 including aporous polymeric layer 465, a second backer fabric 470 laminated to thesecond side of the second composite layer 460 and a second bi-componentlayer 480 laminated to the first side of the second composite layer 480.The first textile laminate 400 is to be joined at a seam 500 to thesecond textile laminate 450 using a heat seal die 510. The heat sealmachine used was a Theller Heat seal machine which is available fromTheller Engineering in Petaluma, Calif., USA.

Alternatively ultrasonic welding can be used in order to form the seams500. For example a Branson Ultrasonic Sealer available from BransonUltrasonics Corporation of Danbury, Conn., USA, is used.

The optional use of the propellant to create a foam at the seam 500creates a seam which is both substantially waterproof and impartsimproved hand to the seam 500.

In FIG. 4, it should be observed that the bi-component layers 430 and480 are depicted immediately before melting.

The temperature of the heat seal die is chosen to be greater than thatof the melting temperature of the second low melting temperaturecomponent of the bi-component layers 400 and 450 but to be below themelting temperature of the first component of the bi-component layers430 and 480. Typically the heat seal die is at a temperature of between130° C. and 215° C. A pressure of 60 psi-300 psi and a dwell time ofbetween 1 s and 20 s are used. Under these conditions, the low meltingtemperature components in the bicomponent layers 430 and 480 melt and,due to the pressure exerted on the textile laminates 400 and 450 by theheat seal die, the bicomponent layers 430 and 480 fuse together.

The low melting component fills the gaps in the bicomponent layer 430 adbetween the structure formed by the fibres having a higher meltingtemperature. The higher melting temperature fibres serve therefore twofunctions. Firstly they provide mechanical strength to the seam.Secondly they act as a “gap-keeper” or spacer to ensure that the lowermelting temperature fibres in the molten state to not seep out of theseam 500.

The width of the seam 500 formed is between 0.5 mm and 1.3 cm.

If a propellant is included in the bi-component layer 430, 480, thenthis is activated by the heat produced by the heat seal die and a closedcell foam is produced at the seam 500. Temperature is applied to asufficiently wide area of the seam 500 for a sufficient length of timeto ensure that the seam is watertight. Typically the seam would have awidth of 1-3 mm and the temperature would be applied at 190° C. for 1-10seconds.

The function of the two components in the bi-component layers 430 and480 can be easily understood from FIG. 4. The first component providesmechanical strength to the seam 500 since it neither melts nor otherwisedisintegrates at the temperature to which the seam 500 is subjected bythe heat seal die 510. The second (low melting temperature) componentprovides the adhesive between the two laminates 400 and 450. If apropellant is used, then the second component together with the firstcomponent provides the walls of the cells of the closed-pore foam withsufficient strength to carry any load to which the seam 500 issubjected. Furthermore, the second component imparts sufficient wallstrength to the individual cells to prevent them from connecting witheach other to prevent them from providing a leak path through the seam500 during flexing of the laminates 400, 450.

Another method of adding energy to the bi-component layers 430, 480 toform the seam 500 is to use ultrasonic welding techniques to heat up thecomponents.

In the examples given below the weight of the bi-component layer 30 isgenerally between 0.7 and 1.0 osy. It would be possible to usebi-component layers of higher weight in which case it would be expectedthat the seam strengths would increase since more native material isavailable to form the seam 500 and also more material is available toprovide structure to the seam 500. The first and second backer fabrics420, 470 have weights which are typically between 0.5 osy and 5.5 osy.Different proportions of each component can be used. It is thought thata minimum of 30% by volume of the second component should be present anda maximum of 70% by volume.

An advantage of using the propellant to form the close-cell foam is thatthe seam thus created is substantially more flexible and softer to touchthan a seam formed without the foam created by the molten secondcomponent with the propellant.

The seam is deemed to be waterfight when the water entry pressure of theseam is greater than 0.13 bar when measured using the suture test asexplained above.

In the example illustrated in FIG. 4, it is assumed that thebi-component layers 430 and 480 are fused to each other.

It is also possible to fuse a bi-component layer 430, 480 directly toone of the backer fabrics 470 or 420 as is shown in FIG. 5 in which thecomponents of the textile laminates are given the same numerals as theircounterparts in FIG. 4. Use of the propellant in this example has theadvantage that the molten second component is “blown” into the backerfabric 420, 470, thus creating a substantially more watertight seam.

A further application of the invention is depicted in FIG. 6 in which atwo layer textile laminate 600 comprising a composite layer 610 and abacker fabric 620 is to be joined to a three layer textile laminate 650with a composite layer 660, a first backer fabric 670 on a first side ofthe composite layer 660 and a second backer fabric 680 on a second sideof the composite layer 660. A seam 630 between the two layer textilelaminate 600 and the three layer textile laminate 650 is sealed by atape 700 made from the textile laminate according to the invention. Thetextile laminate has a composite layer 710 with a backer fabric 720 onthe side of the composite layer 710 facing away from the seam and abi-component layer 730 on the side of the composite layer 710 facing theseam 630.

A further application of the invention is shown in FIG. 7 in which apinhole 800 is made in a textile laminate 810 comprising a compositelayer 820 with a backer fabric 830 on a first side and a bi-componentlayer 840 on a second side. The pinhole 800 can be sealed by heating thebi-component layer 840 in the region surrounding the pinhole such thatthe molten low melting temperature component in the bi-component layer840 seals the pinhole 800. The melting point of the low meltingtemperature component is defined to be the temperature at which the lowmelting temperature component flows sufficiently to seal the pinhole800.

EXAMPLES Comparative Example A

A 0.7 osy polyamide 6.6 (nylon) spun-bonded non-woven layer waslaminated to a waterproof breathable composite layer 5 consisting apolyurethane coated ePTFE membrane 10 using the lamination describedabove to produce a textile laminates 1. The polyamide layer 30 isavailable from CEREX Advanced Fabrics in Pensacola, Fla., USA, under thetrade name PBNII. The polyamide sides of two pieces of textile laminates1 are joined together using the Theller Hot Tack Seal Strength Tester.The heat sealing die was 12.7 mm by 133 mm and the actual footprint usedmeasured 12 mm by 131 mm. The top and bottom dies were heated to atemperature of 255° C. and a 5 sec. dwell time was used at a pressure of300 psi.

Comparative Example B

A 0.8 osy polypropylene spun-bonded non-woven layer was laminated to awaterproof breathable composite layer 5 consisting a polyurethane coatedePTFE membrane 10 using the lamination described above to produce atextile laminates 1. The polypropylene layer is available from SnowFiltration Company in West Chester, Ohio, USA, under the trade nameSnopro8. The polypropylene sides of two pieces of textile laminates 1are joined together using the Theller Hot Tack Seal Strength Tester. Theheat sealing die was 12.7 by 133 mm and the actual footprint used was 12mm by 131 mm. The top and bottom dies were heated to a temperature of165° C. and a 5 sec. dwell was used at a pressure of 300 psi.

Comparative Example C

A 60 g/m² polyethylene spun-bonded non-woven layer was laminated to awaterproof breathable composite layer 5 consisting of a polyurethanecoated ePTFE membrane 10 using the lamination described above to producea textile laminates 1. The polyethylene layer is available from SnowFiltration Company in West Chester, Ohio, USA, under the trade nameCorolind T60F00. The polyethylene sides of two pieces of textilelaminates 1 are joined together using the Theller Hot Tack Seal StrengthTester. The heat sealing die was 12.7 by 133 mm and the actual footprintused was 12 mm by 131 mm. The top and bottom dies were heated to atemperature of 130° C. and a 5 sec. dwell was used at 300 psi.

Comparative Example D

A 0.8 osy polyester spun-bonded non-woven layer was laminated to awaterproof breathable composite layer 5 consisting of a polyurethanecoated ePTFE membrane using the lamination described above. Thepolyester layer is available from Snow Filtration Company in WestChester, Ohio, USA, under the trade name Reemay 2011. The polyestersides of two pieces of textile laminates 1 are joined together using theTheller Hot Tack Seal Strength Tester. The heat sealing die was 12.7 by133 mm and the actual footprint used was 12 mm by 131 mm. The top andbottom dies were heated to a temperature of 255° C. and a 5 sec. dwellwas used at a pressure of 300 psi.

Example 1

A 0.8 osy polyethylene (PE)/polyamide (PA) sheath-core spun-bondedbi-component non-woven layer 30 was laminated to a waterproof breathablecomposite layer 5 consisting of a polyurethane coated ePTFE membrane 10using the lamination method described above. The bi-component layer 30was produced by Kimberly-Clark in Roswell, Ga., USA, and is described inU.S. Pat. No. 5,662,978. The bi-component layer 30 sides of the twopieces of textile laminates 1 are joined together using the Theller HotTack Seal Strength Tester. The heat sealing die was 12.7 by 133 mm andthe actual footprint used was 12 mm by 131 mm. The top and bottom dieswere heated to a temperature of 135° C. and a 5 sec. dwell was used at apressure of 300 psi.

Example 2

A 20 g/m² polyethylene (PE)/polyethylene terephthalate (PET) sheath-corespun-bonded bi-component non-woven layer 30 was laminated to awaterproof breathable composite layer 5 consisting a polyurethane coatedePTFE membrane 10 using the lamination described above to form a textilelaminates 1. The bi-component layer 30 was produced by Unitika in Osaka,Japan, and is sold under the brand name ELEVES. The bi-component layersides of two pieces of textile laminates 1 are joined together using theTheller Hot Tack Seal Strength Tester. The heat sealing die was 12.7 by133 mm and the actual footprint used measured was 12 mm by 131 mm. Thetop and bottom dies were and a 5 sec. dwell was used at a pressure of300 psi.

Example 3

A 0.8 osy. polypropylene (PP)/polyethylene terephthalate (PET)sheath-core carded bi-component non-woven layer 30 was laminated to awaterproof breathable composite layer 5 consisting a polyurethane coatedePTFE membrane 10 using the lamination described above to form a textilelaminates 1. The bi-component layer 30 was produced by HDK Industries,Inc., in Rogersville, Tenn., USA, and is sold under part number D1640.The bi-component layer sides of two pieces of textile laminates 1 arejoined together using the Theller Hot Tack Seal Strength Tester. Theheat sealing die was 12.7 by 133 mm and the actual footprint usedmeasured was 12 mm by 131 mm. The top and bottom dies were heated to atemperature of 165° C. and a 5 sec. dwell time was used at a pressure of300 psi.

Example 4

A 0.8 osy. PE/polyethylene terephthalate (PET) sheath-core cardedbi-component non-woven was laminated to a waterproof breathablecomposite layer consisting a polyurethane coated ePTFE membrane usingthe lamination described above. The bi-component layer 30 was producedby HDK Industries, Inc., in Rogersville, Tenn., USA, and is sold underpart number style 115. The bi-component sides of two pieces of theTextile laminates 1 are joined together using the Theller Hot Tack SealStrength Tester. The heat sealing die was 12.7 by 133 mm and the actualfootprint used measured was 12 mm by 131 mm. The top and bottom dieswere heated to a temperature of 130° C. and a 7 sec. dwell was used at apressure of 300 psi.

Example 5

A 30 g/m² polyethylene terephthalate (PET)/PE island in the seabi-component non-woven layer 30 was laminated to a waterproof breathablecomposite layer 5 consisting a polyurethane coated ePTFE membrane 10using the lamination described above to form a textile laminates 1. Thebi-component layer 30 was produced by Unitika in Osaka, Japan, and issold under the brand name ALICMA. The bi-component layer sides of twopieces of textile laminates 1 are joined together using the Theller HotTack Seal Strength Tester. The heat sealing die was 12.7 by 133 mm andthe actual footprint used measured was 12 mm by 131 mm. The top andbottom dies were heated to a temperature of 135° C. and a 5 sec. dwelltime was used at a pressure of 300 psi.

Example 6

A 1.0 osy. polyethylene (PE)/polyamide (PA) sheath-core spun-bondedbi-component non-woven layer 30 was laminated to a waterproof breathablecomposite layer 5 consisting a polyurethane coated ePTFE membrane 10using the lamination described above to form a textile laminates 11. Thebi-component layer 30 was produced by Kimberly-Clark in Rosewell, Ga.,USA, and is described in U.S. Pat. No. 5,662,978. The bi-component layersides of two pieces of textile laminates 1 are joined together using theheat sealing die with 0.1 inch seal width shown in FIG. 4 in the shapeof a glove at about 215° C. for 1.5 sec at a pressure of 470 psi to forma glove insert.

Example 7

A third layer 40 of 0.7 osy non-woven nylon (polyamide 6.6) was added tothe textile laminates 1 in example 6 using the same laminationtechnique. The nylon layer was produced by CEREX. Advanced Fabrics inPensacola, Fla., USA, and sold under the trade name PBN2. Thebi-component layer sides of the two pieces of textile laminates 1 arejoined together using the heat sealing die with 0.7 mm seal width shownin FIG. 4 in the shape of a glove at about 215° C. for 2.0 sec at apressure of 470 psi to form a glove insert.

Example 8

A 0.8 osy. polyethylene/polyamide (PA) sheath-core spun-bondedbi-component non-woven layer 30 was laminated to a waterproof breathablecomposite layer 5 consisting a polyurethane coated ePTFE membrane 10using the lamination described above to form a textile laminate 1. Athird layer 40 of 0.7 osy non-woven nylon (polyamide 6.6) was added tothe textile laminate 1 using the same lamination technique. The nylonlayer was produced by CEREX Advanced Fabrics in Penascola, Fla., USA,and is sold under the trade name PBNII. The bi-component layer sides oftwo pieces of textile laminates 1 are joined together using the heatsealing die with 0.1 inch seal width shown in FIG. 4 in the shape of aglove at a temperature of about 200° C. for a dwell time of 2.0 sec anda pressure of 470 psi to form a glove insert.

Example 9

The textile laminates 1 in example 8 were repeated in which the thirdlayer 40 is 1.8 osy brushed knit available from International Foam. Thebi-component layer sides of the two pieces of textile laminate 1 arejoined together using the heat sealing die with 0.7 mm seal width shownin FIG. 4 in the shape of a glove at a temperature of about 190° C. for5 sec. at a pressure of 400 gauge psi to form a glove insert.

Example 10

The textile laminates 1 in example 8 were repeated in which the thirdlayer 40 is 5.5 osy cotton. The bi-component layer sides of two piecesof the textile laminates 1 are joined together using the heat sealingdie with 0.1 inch seal width shown in FIG. 4 in the shape of a sock at atemperature of about 230° C. for 10 sec and at a pressure of 440 gaugepsi to form a sock.

Example 11

The textile laminates in example 8 were used to form waterproof seams byultrasonic welding. The bi-component layer sides of the two pieces oftextile laminates 1 are joined together using a Branson UltrasonicSealer Model FS90 with a 0.5 mm horn to make 0.5 mm seams. An amplitudeof 75%, a pressure of 20 psi and speed of 1 were used.

Example 12

The textile laminates in example 9 were used to form waterproof seams byultrasonic welding. The bi-component sides of two pieces of Textilelaminates 1 are joined together using a Branson Ultrasonic Sealer ModelFS90 with a 0.5 mm anvil to make 0.5 mm seams. An amplitude of 75%, apressure of 20 psi and speed of 1 were used.

Example 13

A third layer 40 of 20 g/m² non-woven nylon layer was added to thetextile laminates 1 of example 2 using the same lamination technique.The nylon layer 40 was produced by ASAHI in Japan and sold under thetrade name N1020. The bi-component layer sides of the two pieces oftextile laminates 1 are joined together using the heat sealing die with1 inch seal width shown in FIG. 4 in the shape of a glove at atemperature of about 200° C. for 7 sec. A pressure of 55 gauge psi wasused to form a glove insert.

Example 14

The textile laminate 1 of example 3 was used to make a glove insert. Thebi-component layer sides of two pieces of textile laminates 1 are joinedtogether using the heat sealing die with 0.1 inch seal width shown inFIG. 4 in the shape of a glove at a temperature of about 200° C. for 5sec and a pressure of 55 gauge psi to form a glove insert.

Example 15

A third layer 40 of 0.7 20 g/m² non-woven nylon layer 40 was added tothe textile laminate 1 in example 4 using the same lamination technique.The nylon layer 40 was produced by Asahi in Japan and is sold under thetrade name N1020. The bi-component sides of two pieces of textilelaminate 1 are joined together using the heat sealing die with 0.1 inchseal width shown in FIG. 4 in the shape of a glove at about 200° C. for7 sec at a pressure of 55 gauge psi to form a glove insert.

Example 16

The textile laminates 1 of Example 5 was used to make a glove insert.The bi-component layer sides of two pieces of the textile laminates 1are joined together using the heat sealing die with 0.1 inch seal widthshown in FIG. 4 in the shape of a glove at about 200° C. for 5 sec at apressure of 55 gauge psi to form a glove insert.

Example 17

The textile laminates 1 in example 1 were repeated except that thewaterproof breathable layer is a waterproof breathable layer ofpolypropylene. The polypropylene layer is available from Du Pont ofWilmington, Del. under the brand name TYVEK part number 1422A. Thebi-component sides of two pieces of textile laminates 1 are joinedtogether using the Theller Hot Tack Seal Strength Tester. The heatsealing die was 12.7 by 133 mm and the actual footprint used measuredwas 12 mm by 131 mm. The top and bottom dies were heated to 130° C. anda 5 sec. dwell time was used at a pressure of 110 psi.

Example 18

The textile laminates 1 of example 1 were repeated except that thewaterproof breathable layer is a waterproof breathable layer ofpolyurethane. The polyurethane layer is available from B F Goodrichunder the brand name ESTHANE. The bi-component sides of two pieces oftextile laminates 1 are joined together using the Theller Hot Tack SealStrength Tester. The heat sealing die was 12.7 by 133 mm and the actualfootprint used measured was 12 mm by 131 mm. The top and bottom dieswere heated to 135° C. and a 7 sec. dwell time was used at a pressure of300 psi (Example 18A) and 110 p.s.i. (Example 18B).

Example 19

The textile laminates 1 of example 1 were repeated except that where thewaterproof breathable layer is a waterproof breathable layer ofpolyurethane. The polyurethane layer is described in PCT ApplicationUS94/124659. The bi-component layer sides of two pieces of textilelaminates 1 are joined together using the Theller Hot Tack Seal StrengthTester. The heat sealing die was 12.7 by 133 mm and the actual footprintused measured was 12 mm by 131 mm. The top and bottom dies were heatedto 130° C. and a 7 sec. dwell time was used at a pressure of 110 psi.

Example 20

The textile laminates 1 in example 1 were repeated except that thewaterproof breathable layer is a waterproof breathable layer of ePTFEwhich is not coated with polyurethane. The bi-component layer sides oftwo pieces of textile laminates 1 are joined together using the ThellerHot Tack Seal Strength Tester. The heat sealing die was 12.7 by 133 mmand the actual footprint used measured was 12 mm by 131 mm. The top andbottom dies were heated to a temperature of 135° C. and a 7 sec. dwelltime was used at a pressure of 300 psi.

Example 21

A 0.7 osy non-woven nylon layer 40 was laminated to a waterproofbreathable composite layer 5 consisting a polyurethane coated ePTFEmembrane 10 using the lamination described above. The nylon layer 40 wasproduced by CEREX Advances Fabrics in Pensacola, Fla., USA under thetrade name PBNII. The bi-component layer side of the textile laminate 1of example 8 and the nylon side for the textile laminates 1 describedhere were joined together using the Theller Hot Tack Seal StrengthTester. The heat sealing die was 12.7 by 133 mm and the actual footprintused measured was 12 mm by 131 mm. The top and bottom dies were heatedto a temperature of 135° C. and a 5 sec. dwell was used at a pressure of300 psi.

Results

Polyethylene/Polyamide Bi-Component Layer

Table 2 shows the results of laminating the polyethylene/polyamidebi-component layer of Kimberley-Clark to a variety of membranes.

TABLE 2 Ex- seam MVTR MVTR Passed ample strength (m²/24 hr) (m²/24 hr.)Suter No. Membrane (pli) Membrane Laminate Test? 17 Tyvek 5,8 3830 3095pass 1 Poly- 6,4 9536 14829 pass urethane- coated ePTFE 19 Polyurethan 55647 6392 pass 20 ePTFE 5,3 14084 13019 pass 18 Polyurethan 7.4 (18A)/3472 3784 pass 3.1 (18B)

The column “passed suter test” indicates whether the seam formed wasable to withstand water at a pressure of 2 psi for at least 3 minutes.The seam strength measurements on example 18 were repeated twice asexplained above. The better strength was obtained when the higherpressure was used.

Seam Strength and Seam Width

Table 3 shows the seam strength in pounds per linear inch (pli) and theseam width for a number of examples of the patent constructed in theform of a glove, sock or just a seam.

TABLE 3 Seam Example Strength WGLT Passed Seam Number Object Made (pli)(PSI) Suter Test? Width 6 glove 5,8 9 0.1 in 7 glove 6,4 8 0.7 mm 8glove 5,8 14 0.1 in 9 glove 9.3 14 0.1 in 10 sock 5,4 6 0.1 in 13 glove5,4 11 0.1 in 14 glove 5.0 8 0.1 in 15 glove 5.2 11 0.1 in 16 glove 5.76 0.1 in 11 seam 7,7 pass 0.5 mm 12 seam 9,5 pass 0.5 mm 21 seam pass0.5 in

WGLT=Whole Glove Leak Test, see U.S. Pat. No. 4,776,209

Measurements on Textile Prior to Formation of Laminate

Table 4 shows measurement made on the raw textiles prior to theformation of the laminate.

TABLE 4 Long. Trans. (Bulk Bulk Long. Tensile Long. Trans. TensileTrans. Average Bulk Trans. Example Weight Thickness Break StrengthStrain Break Strength Strain Tensile Strain No. Material (g/3 × 1 in²)(in) (pounds) (PSI) (%) (pounds) (PSI) (% elongate.) Strength (PSI) (%elong.) B PP 0.05 0.008 5.2  650 57.3 3.2  400 63.8  525 60.6 C PE 0.110.013 6.3  485 289.5 3.6  277 311.7  381 300.6 A PA 0.05 0.006 7.9 131774.3 4.7  783 66.7 1050 70.5 D PET 0.06 0.008 8 1000 48.2 3.6  450 55.1 725 51.7 1 PE/PA 0.05 0.005 9.5 1900 76 4.8  960 94.1 1430 85.1 2PE/PET 0.04 0.005 9.3 1860 79.9 4.3  860 76.9 1360 78.4 5 PET/PE 0.060.008 4.9  613 29.7 2.7  338 36.6  476 33.2 4 PE/PET 0.05 0.004 6.3 157554.5 1.7  425 74.4 1000 64.5 3 PP/PET 0.05 0.003 7.7 2567 37.2 3.1 103326.6 1800 31.9 ePTFE Not 0.06 0.001 2.2 2200 188.4 4.5 4500 60.4 3350Laminated

In table 4, the measurements are made in either the transverse or in thelongitudinal direction. These directions are perpendicular to each otherand indicate the direction in which the seam (500) in the laminate 1 isto be formed. The longitudinal direction is the direction along the seam(500) whilst the transverse direction is the direction across the seam(500).

Measurements on Laminates

Table 5 shows the results of measurements made on the seams formed inthe laminates.

TABLE 5 Long. Trans. Long. Bulk Long. Trans. Bulk Trans. LaminateLaminate Break Tensile Strain Break Tensile Strain Av. Bulk WeightThickness Strength Strength (% strain Strength Strength (% strainTensile Ex. No. (g/in²) (in) (lbs) (psi) % elong.) (lbs) (psi) % elong.)Strength MVTR B 0.12 0.0096 8.2  854.2 82.3 7.4  770.8 82.8  812.5  8985C 0.18 0.0132 8.9  674.2 279 6.1  462.1 107.3  568.2  9650 A 0.11 0.007 9.4 1342.9 99.6 9.0 1371.4 70 1357.1 10795 D 0.11 0.009  9.4 1044.4 59.310.1 1511.1 73 1277.8 11276 1 0.14 0.009  12.1 1344.4 122.4 8.0  988.999.5 1166.7  9750 2 0.10 0.006  13 2166.7 91.2 8.9 2283.3 85.3 2225.010912 5 0.11 0.008  5.5  687.5 41.9 8.8 1612.5 41 1150.0  9159 4 0.130.0046 9.3 2021.7 66.4 6.8 1478.3 67.8 1750.0  9912 3 0.12 0.0042 10.62523.8 47.5 9.3 2214.3 53.1 2369.0 10352

Measurements on Seams

Table 6 shows the results of measurements made on the seams formed inthe laminates. A three inch by one inch sample was used.

TABLE 6A Seam Seam Seam Long. Seam Seam Trans. Seam Seam Av. Long. BulkLong. Trans. Bulk Trans. Bulk Seam Av. Seam Break Tensile Strain BreakTensile Strain Tensile Strain (% Ex. Seam Thickness Strength Strength (%Strength Strength (% Strength elong. At No. Weight (in) (lbs) (PSI)elong.) (lbs) (psi) elong.) (psi) break) B 0.25 0.0073 15.2 2082 58 15.42110 57 2096  58 C 0.4  0.0123 14.3 1163 277.6 14.3 1163 88.2 1163 183 A0.23 0.008  18.4 2300 89.2 22.4 2800 78.1 2550  84 D 0.23 0.005  17.43480 64.2 20.9 4180 69.7 3830  67 1 0.28 0.007  28.6 4086 130.5 21.23029 117.3 3557 124 2 0.21 0.005  28 5600 94.9 20.8 4160 86.8 4880  91 50.23 0.005  17.2 3440 56.9 19.2 3840 44 3640  50 4 0.24 0.006  19.3 321776.1 14 2333 78.9 2775  78 3 0.23 0.005  21.4 4280 48.3 17.8 3560 50.53920  49

TABLE 6B Seam Suter Shrin Seam Suter Test Test on Width of Length Ex.k-age Strengt on 1 in. 0.5 in Seam of Seam No. (%) h (pli) Seam Seam(mm) (mm) B 7.1 3.2 3 pass 3 pass 11.6 125.8 C 2.2 3.2 3 pass 3 pass12.0 128.2 A 20.5 7.7 3 pass 3 pass 10.1 123.8 D 17.5 6 3 pass 3 pass10.3 125.5 1 5 6-7 3 pass 3 pass 11.6 128.7 2 5.5 5 0 pass 3 pass 11.5129.2 5 3.3 3.3 3 pass 3 pass 11.8 128.8 4 5.2 5.8 3 pass 3 pass 11.6128.5 3 4.1 5.1 3 pass 3 pass 11.7 128.8

It will be observed from this table that the seam shrinkage of theexamples 1-5 is low compared to that of the comparative examples A andD.

Cantilever Test

This test is designed to measure the stiffness of the laminate and theresults are shown in Table 7.

TABLE 7 Seam Seam Seam Seam Seam Seam Long. Long. Long. Seam Trans.Trans. Trans. Seam Seam cantilever cantilever cantilever Long.cantilever cantilever cantilever Trans. Av. Ex. width thickness testcantilever width thickness test cantilever cantilever No. mm mm cm 1/mmmm mm cm 1/mm 1/mm B 12 0.18 9.9 45.83 11.8 0.18 9.6 45.20 45.5 C 12.20.23 10.3 36.71 12 0.23 11.4 41.30 39.0 A 10 0.14 7.7 55.00 10.6 0.147.4 49.87 52.4 D 11 0.13 10.7 74.83 10.6 0.12 9.3 73.11 74.0 1 12.1 0.177.3 35.49 11.7 0.17 6.9 34.69 35.1 2 12 0.13 6.1 39.10 12.2 0.14 7.543.91 41.5 5 11.8 0.14 6.4 38.74 11.8 0.15 6.6 37.29 38.0 4 12.1 0.167.5 38.74 11.4 0.16 6.6 36.18 37.5 3 12.1 0.14 7.8 46.04 11.4 0.14 7.245.11 45.6

The result in the last column is indicative of the stiffness of the seam500. It will be observed that the examples with the bi-component layers30 have a lower average cantilever measurement (stiffness) than thecomparative examples. Comparative example C and B do have a low averagecantilever measurement. It will be seen, however, from table 6 that theseam transverse breaking strength (3.2 lbs) is comparatively low.Comparative example A has a low average cantilever measurement, althougha higher value than the measurements on examples 14. The seam shrinkage(table 6B) is, however, 20.5% which is high.

What is claimed is:
 1. A combination of a laminate (400) and a substrate(450, 650) comprising a waterproof substrate (450, 650); and a laminate(400) joined to said substrate (450, 650) at a waterproof seam (500),the laminate (400) having a first layer (5) comprising a waterprooffunctional layer (10, 20), and a second layer (30) laminated to saidfirst layer (5), the second layer including a plurality of yarns havingat least a bicomponent structure of at least a first component and asecond component, the first component being stable to a firsttemperature and the second component melting at a second temperature,wherein the first temperature is higher than the second temperature andwherein the second component has been heated and melted to form thewaterproof seam between the laminate and the waterproof substrate. 2.The combination of claim 1, whereby the seam (500) withstands a waterentry pressure of at least 0.07 bar.
 3. The combination of claim 1,whereby the seam (500) withstands a water entry pressure of at least0.13 bar.
 4. The combination of claim 1, whereby the stiffness of theseam (500) is less than 50 mm⁻¹.
 5. The combination of claim 1, wherebythe shrinkage of the seam (500) is less than 7%.
 6. The combination ofclaim 1, whereby the seam (500) has a width less than 0.25 cm.
 7. Thecombination of claim 1, whereby the seam (600) has an elongation strainat break of greater than 75%.
 8. The combination of claim 1, whereby theseam (500) has a transverse seam strength of greater than 3 pli.
 9. Thecombination of claim 1, whereby the second layer (30) further includes apropellant which is activatable by activation means.
 10. The combinationof claim 9, wherein the propellant is selected from the group ofpropellants consisting of azodicarbonamide, ammonium hydrogen carbonate,toluolsulfohydrazin or diazoaminobenzol.
 11. The combination of claim10, wherein the propellant is azodicarbonamide.
 12. The combination ofclaim 9, wherein the propellant after activation generates a closed cellfoam with the second component after melting.
 13. The combination ofclaim 9, wherein the propellant is activated at a temperature betweenthe second temperature and the first temperature.
 14. The combination ofclaim 9, wherein the propellant is an integral part of the secondcomponent.
 15. The combination of claim 1, whereby the second componentmelts at a temperature In the range of from 80° C. to 170° C.
 16. Thecombination of claim 1, whereby the first component does not melt belowa temperature of 140° C.
 17. The combination of claim 1, whereby thefirst component does not disintegrate below a temperature of 140° C. 18.The combination of claim 1, whereby the difference in temperaturebetween the first temperature and the second temperature is at least 20°C.
 19. The combination of claim 1, wherein the second layer (30) is aknitted, woven or non-woven layer.
 20. The combination of claim 1,wherein the first component is selected from the group of polymerscomprising polyolefins, polyester, copolyester, polyamide, coolyamide,cellulose or protein fibers.
 21. The combination of claim 20, whereinthe first component is polyamide 6.6.
 22. The combination of claim 20,wherein the first component is a polyolefin selected from polypropyleneand polyethylene.
 23. The combination of claim 20, wherein the firstcomponent is a protein fiber selected from wool and silk.
 24. Thecombination of claim 1, wherein the second component is a thermoplastic.25. The combination of claim 24, wherein the second component isselected from the group of thermoplastics comprising co-polyester,polyamide, co-poyamide or polyolefin.
 26. The combination of claim 25,wherein the second component is a polyethylene.
 27. The combination ofclaim 25, wherein the second component is a polyamide
 6. 28. Thecombination of claim 25 wherein the second component is a polypropylene.29. The combination of claim 1, wherein the yarn has a cover-corestructure, wherein the second component forms the cover.
 30. Thecombination of claim 1, wherein the yarn has a “side-by-side” structure.31. The combination of claim 1, wherein the second layer is a blend ofsaid plurality of yarns.
 32. The combination of claim 1, wherein theyarn is comprised of fibers.
 33. The combination of claim 1, wherein thefunctional layer (5) is a membrane or a film.
 34. The combination ofclaim 33, wherein the functional layer (5) is selected from the group ofmaterials consisting of polyesters, polyamide, polyolefins,polyvinylichloride, polyketones, polysutfones, polycarbonates,fluaropolymers, polyacrylates, poiyurethanes, co-polyetheresters, andco-polyetheramides.
 35. The combination of claim 34, wherein thefunctional layer (5) Is made from expanded PTFE.
 36. The combination ofclaim 34, wherein the functional layer is polytetrafluoroethylene(PTFE).
 37. The combination of claim 1, wherein the MVTR of the laminate(400) is less than 150 RET.
 38. The combination of claim 1, wherein thewater entry pressure of a laminate (400) is greater than 0.13 bar. 39.Articles of clothing made from the combination of claim
 1. 40. Thecombination of claim 1 wherein the waterproof substrate comprises atleast a waterproof laminate (400, 450), having a functional layer (10,20) laminated to a textile layer (30) wherein the waterproof seam (500)has a transverse seam strength of greater than 3 pli and an elongationstrain at break greater than 75%.
 41. The combination of claim 40,wherein the seam (500) has a width of less than 0.25 cm.
 42. Thecombination of claim 40, wherein the stiffness of the seam (500) is lessthan 50 mm⁻¹.
 43. The combination of claim 40, wherein the seam (500)withstands water pressure of 0.13 bar for at least three minutes. 44.The combination of claim 40, wherein the seam (500) shrinks by less than7% after welding.
 45. The combination of claim 1 wherein the waterproofsubstrate comprises at least a waterproof laminate (400, 450), having afunctional layer (10, 20) laminated to a textile layer (30), wherein thewaterproof seam (500) has a transverse seam strength of greater than 3pli and wherein the stiffness of the seam (500) is less than 50 mm⁻¹.46. The combination of claim 45, wherein the seam (500) has a width ofless than 0.25 cm.
 47. The combination of claim 45, wherein elongationstrain at break is greater than 75%.
 48. The combination of claim 45,wherein the seam (500) withstands a water pressure of 0.13 bar for atleast three minutes.
 49. A combination of two laminates (400, 450, 650)joined together at a waterproof seam (500), each of the laminates (400,450, 650) comprises: a first layer (5) comprising a waterprooffunctional layer (10, 20), and a second layer (30) laminated to saidfirst layer (5), the second layer including a plurality of yarns havingat least a bicomponent structure of at least a first component and asecond component, the first component being stable to a firsttemperature and the second component melting at a second temperaturewherein the first temperature is higher than the second temperature, andwherein the second component has been heated and melted to form thewaterproof seam between the two laminates.
 50. The combination of claim49, whereby the seam (500) withstands a water entry pressure of at least0.13 bar.
 51. The combination of claim 49, whereby the seam (500) has awidth less than 0.25 cm.
 52. The combination of claim 49, whereby theseam (500) has an elongation strain at break of greater than 75%. 53.The combination of claim 49, whereby the seam (500) has a transverseseam strength of greater than 3 pli.
 54. The combination of claim 49,whereby the stiffness of the seam (500) is less than 50 mm⁻¹.
 55. Thecombination of claim 49, whereby the shrinkage of the seam (500) is lessthan 7%.
 56. The combination of claim 49, whereby the second layerfurther includes a propellant which is activatable by activation means.57. The combination of claim 56, wherein the propellant after activationgenerated a closed cell foam with the second component after melting.58. The combination of claim 56, wherein the propellant is activated ata temperature between the second temperature and the first temperature.59. The combination of claim 56, wherein the propellant is an integralpart of the second component.
 60. The combination of claim 56, whereinthe propellant is selected from the group of propellants consisting ofazodicarbonamide, ammonium hydrogen carbonate, toluoisulfohydrazin ordiazoaminobenzol.
 61. The combination of claim 60, wherein thepropellant is azodicarbonamide.
 62. The combination of claim 49, wherebythe second component melts at a temperature in the range of from 80° C.to 170° C.
 63. The combination of claim 49, whereby the first componentdoes not melt below a temperature of 140° C.
 64. The combination ofclaim 49, whereby the first component does not disintegrate below atemperature of 140° C.
 65. The combination of claim 49, whereby thedifference in temperature between the first temperature and the secondtemperature is at least 20° C.
 66. The combination of claim 49, whereinthe first component is selected from the group of polymers comprisingcellulose, protein fibers, polyolefins, polyester, co-polyester,polyamide, and co-polyamide.
 67. The combination of claim 66, whereinthe first component is polyamide 6.6.
 68. The combination of claim 66,wherein the first component is a polyolefin selected from polypropyleneand polyethylene.
 69. The combination of claim 66, wherein the firstcomponent is a protein fiber selected from wool and silk.
 70. Thecombination of claim 49, wherein the second components is athermoplastic.
 71. The combination of claim 70, wherein the secondcomponent is selected from the group of thermoplastics comprisingco-polyester, polyamide, co-polyamide and polyolefin.
 72. Thecombination of claim 71, wherein the second component is a polyethylene.73. The combination of claim 71, wherein the second component Is apolyamide
 6. 74. The combination of claim 70, wherein the secondcomponent is a polyolefin selected from polypropylene and polyethylene.75. The combination of claim 49, wherein the yarn has a sheath-corestructure, wherein the second component forms the cover.
 76. Thecombination of claim 49, wherein the yarn has a “side-by-side”structure.
 77. The combination of claim 49, wherein the yarn iscomprised of fibers.
 78. The combination of claim 49, wherein thefunctional layer (5) Is a membrane or a film.
 79. The combination ofclaim 78, wherein the functional layer (5) Is selected from the group ofmaterials consisting of polyesters, polyamide, polyolefins,polyvinylichloride, polyketones, polysulfones, polycarbonates,fluoropolymers, polyacrylates, polyurethanes, co-polyetheresters, andco-polyetheramides.
 80. The combination of claim 79, wherein thefunctional layer (5) is made from expanded PTFE.
 81. The combination ofclaim 78, wherein the functional layer is polytetrafluoroethylene(PTFE).
 82. The combination of claim 49, wherein the MVTR of thelaminate (1) is greater than 3000 m³/24 hr.
 83. The combination of claim49, wherein the water entry pressure of a laminate (1) is greater than0.13 bar.
 84. The combination of claim 49 in a garment.
 85. Acombination of a laminate (400) and a substrate (450, 650) comprising; awaterproof substrate (450, 660); and a laminate (400) joined to thesubstrate (45), 650) at a waterproof seam (500), the laminate (400)having a first layer (5) comprising a waterproof functional layer (10,20), and a second layer (30) laminated to the first layer (5) andcomprising at least a first component, a second component and apropellant which is activatable by activation means, the first componentbeing stable to a first temperature and the second component melting ata second temperature, wherein the first temperature is higher than thesecond temperature and wherein the second component has been heated andmelted to form the waterproof seam between the laminate and thewaterproof substrate.